Installation, Operating & Maintenance Instructions All-metal gate valve with extended pneumatic actuator Series 48 DN 16 320 mm (I.D. ⅝" 12") This manual is valid for the following product ordering numbers: With weld stubs 48124-RE24-ARG. 48132-RE24-ARG. / ARI. 48236-RE24-ARG. / ARI. 48240-RE24-ARG. / ARI. 48244-RE24-ARG. / ARH. / ARI. 48146-RE24-ARG. / ARH. / ARI. 48148-RE24-ARG. / ARH. / ARI. 48150-RE24-ARG. / ARH. / ARI. With ITER flanges 48236-XE24-APV. 48240-XE24-APV. 48244-XE24-APV. 48146-XE24-APV. 48148-XE24-APV. 48150-XE24-APV. Sample pictures 809878EA Edition 2016-04-14
Imprint Manufacturer VAT Vakuumventile AG, CH-9469 Haag, Switzerland Website: Phone: Fax: Email: www.vatvalve.com +41 81 771 61 61 +41 81 771 48 30 CH@vatvalve.com Publisher VAT Vakuumventile AG, CH-9469 Haag, Switzerland Editor VAT Vakuumventile AG, CH-9469 Haag, Switzerland Print VAT Vakuumventile AG, CH-9469 Haag, Switzerland Copyright VAT Vakuumventile AG 2016 No part of these Instructions may be reproduced in any way (photocopies, microfilms or any other reproduction processes) nor may it be manipulated with electronic systems, duplicated or distributed without written permission from VAT. Offenders are liable to pay damages. The original VAT firmware and updated state of the art versions of the VAT firmware are intended for use with VAT products. The VAT firmware contains a limited, time unlimited user license. The VAT firmware may not be used for purposes other than those intended nor is it permitted to make copies of the VAT firmware. In particular, it is strictly forbidden to give copies of the VAT firmware to other people. The use of trade names, brand names, trademarks, etc. in these Instructions does not entitle third parties to consider these names to be unprotected and to use them freely. This is in accordance with the meaning of the laws and acts covering brand names and trademarks. 2/27 Edition 2016-04-14 809878EA
DESCRIPTION OF PRODUCT Contents 1 Description of product... 4 1.1 Identification of product... 4 1.2 Use of product... 4 1.3 Related documents... 4 1.4 Important information... 4 1.5 Technical data... 4 2 Safety... 5 2.1 Compulsory reading material... 5 2.2 Danger levels... 5 2.3 Personnel qualifications... 6 2.4 Safety labels... 6 3 Design and Function... 7 3.1 Design... 7 3.2 Function... 8 4 Installation... 9 4.1 Unpacking... 9 4.2 Installation into the system... 10 4.2.1 Preparation for installation... 11 4.2.2 Mounting to the system... 12 4.3 Compressed air connection... 14 4.4 Electrical connection... 15 5 Operation... 16 5.1 Normal operation... 16 5.2 Operation under increased temperature... 17 5.3 Bake-out... 18 5.4 Behavior in case of air pressure drop... 18 5.5 Behavior in case of power failure... 18 5.6 Trouble shooting... 19 6 Maintenance... 20 6.1 Maintenance intervals... 20 7 Repairs... 21 8 Dismounting and Storage... 22 8.1 Dismounting... 23 8.2 Storage... 23 9 Packaging and Transport... 24 9.1 Packaging... 25 9.2 Transport... 25 10 Disposal... 26 11 Spare parts... 27 809878EA Edition 2016-04-14 3/27
DESCRIPTION OF PRODUCT Series 48 1 Description of product 1.1 Identification of product The fabrication number and order number are fixed on the product directly or by means of an identification plate. made in Switzerland Fabrication No.: 48.. -.... -.... /.... A -...... Fabrication number Order number 1.2 Use of product Use product for clean and dry vacuum applications only. Other applications are only allowed with the written permission of VAT. 1.3 Related documents Product data sheet Dimensional drawing 1.4 Important information This symbol points to a very important statement that requires particular attention. Example: VAT disclaims any liability for damages resulting from inappropriate packaging. 1.5 Technical data See product data sheet. Weight of valves, see product data sheet. 4/27 Edition 2016-04-14 809878EA
SAFETY 2 Safety 2.1 Compulsory reading material Read this chapter prior to performing any work with or on the product. It contains important information that is significant for your own personal safety. This chapter must have been read and understood by all persons who perform any kind of work with or on the product during any stage of its serviceable life. Lack of knowledge Failing to read this manual may result in property damage. Firstly, read manual. These Installation, Operating & Maintenance Instructions are an integral part of a comprehensive documentation belonging to a complete technical system. They must be stored together with the other documentation and accessible for anybody who is authorized to work with the system at any time. 2.2 Danger levels High risk DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Medium risk Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Low risk CAUTION Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury. Command Indicates a hazardous situation which, if not avoided, may result in property damage. 809878EA Edition 2016-04-14 5/27
SAFETY Series 48 2.3 Personnel qualifications Unqualified personnel Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. 2.4 Safety labels Label Part No. Label size (mm) Location on valve DN 16 100: T-9001-155 DN 160 320: T-9001-156 20 20 80 80 On protective covers of flanges 6/27 Edition 2016-04-14 809878EA
DESIGN AND FUNCTION 3 Design and Function 3.1 Design With weld stubs: type 48... - RE24 -... With ITER flanges: type 48... - XE24 -... Figure 3-1 1 Actuator 2 Valve body 3 Connecting flange 4 Sealing surface 5 Distance piece 809878EA Edition 2016-04-14 7/27
DESIGN AND FUNCTION Series 48 3.2 Function Valve is closed and opened pneumatically. Closing: The valve mechanism moves towards the valve opening until it touches the mechanical stop (4). Due to continued pressure, valve gate (1) with the assembled VATRING (7) and counter plate (2) spread apart from the guide plate (3).This effect leaktight closing. Opening: Valve gate (1) and counter plate (2) are retracted and valve mechanism moves back into the valve body. OPEN 4 5 6 3 2 1 7 CLOSED Figure 3-2 (sample pictures) 1 Valve gate 2 Counter plate 3 Guide plate 4 Spring stop 5 Leaf spring 6 Support 7 VATRING Valve seat side 8/27 Edition 2016-04-14 809878EA
INSTALLATION 4 Installation Unqualified personnel Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. Heavy weight Physical overstraining. Use a crane to lift the product. 4.1 Unpacking Make sure that the supplied products are in accordance with your order. Inspect the quality of the supplied products visually. If it does not meet your requirements, please contact VAT immediately. Store the original packaging material. It may be useful if products must be returned to VAT. Open the outer plastic bag protecting the valve only at the points where you need access to the eyebolts (1) for fastening the crane hooks; see «Figure 4-1» on page 10. Keep valve in the plastic bag until it is being installed into the system. Wrong lifting Valve may crash and get damaged. Use only the eyebolts shown in the dimensional drawing and in «Figure 4-1» on page 10 to lift the valve. Using any other components (e. g. position indicators, solenoids) to lift the valve is strictly forbidden. Sensitive product Valve parts may get damaged. When lifting the valve, pay attention that the valve does not touch any solid objects. Lift valve carefully and put it down on a clean surface or mount it to a clean system. 809878EA Edition 2016-04-14 9/27
INSTALLATION Series 48 Use a crane for lifting valve DN100 and higher out of the transport box; see «Figure 4-1». Weight of standard valves; see chapter «1.5 Technical data». 1 Eyebolts 2 Lifting ropes A Valve movement direction B Support required to stabilize the valve Figure 4-1 4.2 Installation into the system Movable parts Human body parts may get jammed and severely injured. Do not connect or supply electrical power and compressed air before the product is completely mounted in the system. Contamination Product may get contaminated. Always wear cleanroom gloves when handling the product. Force effect from other components of the system Valve body may get deformed and/or malfunctions may occur. Do not use valve to support other components. Make sure that forces from other components do not impair the valve; use bellows sections, for instance. 10/27 Edition 2016-04-14 809878EA
INSTALLATION 4.2.1 Preparation for installation Danger of injury in case of insufficient skills Inappropriate handling may cause serious injury or property damage. Make sure that the valve does not topple or fall down while removing the protective covers from the flanges. Sensitive product 1. Remove plastic bag. Valve parts may get damaged. When removing the protective covers from the flanges, be careful to avoid damage to the valve. 2. Remove screws (2) and protective covers (3); see «Figure 4-2». 1 Eyebolts to fasten the crane hooks 2 Protective covers 3 Screws (quantity depends on valve size) 4 Washers (quantity depends on valve size) Figure 4-2 Store screws, protective covers and O-rings. They may be useful when valve needs to be repacked. 3. Clean sealing surfaces; see «Figure 3-1» on page 7, with a cleanroom wiper soaked with pure alcohol (Isopropanol). 4. Clean surface with clean, oil free compressed air. 809878EA Edition 2016-04-14 11/27
INSTALLATION Series 48 4.2.2 Mounting to the system The valve seat side is marked with the symbol on flange «A»; see «Figure 4-3». 1 Flange B 2 Flange A 3 Marking for valve seat side (symbol ) 4 VCR ports 5 Screw holes Figure 4-3 1. Mount valve to your system by using appropriate flange screws resp. by welding it into your vacuum system. 2. Please follow following sequence provided by the ITER Organization. The sequence is related to «Figure 4-4» and the table of bolt torques. a. Flanges cleaned and prepared for installation, b. Valve supported if required and mounted with seal in place. c. All bolts installed clean and finger tight. d. Tighten in a star pattern to 25% final value. e. Tighten in a star pattern to 50% final value. 12/27 Edition 2016-04-14 809878EA
INSTALLATION f. Tighten in a star pattern to 100% final value. g. Check flange has pulled up to make contact. h. Re Tighten in a star pattern to 100% final value. i. Remove support if used. j. Leak check. Figure 4-4 Valve size Bolt Thread Bolt Torque Assumes µ = 0.2 [Nm] DN 63 DN 100 DN 160 M16 186 DN 200 DN 250 DN 320 M16 186 809878EA Edition 2016-04-14 13/27
INSTALLATION Series 48 4.3 Compressed air connection Valve in open or closed position Risk of injury when compressed air is connected to the valve. Connect compressed air only when: valve is installed in the vacuum system moving parts cannot be touched Wrong sequence of connections Valve mechanism may get damaged when electrical power is being connected before compressed air is connected. Always connect compressed air before connecting electrical power. Use clean, dry or slightly oiled air only. Admissible air pressure range, see product data sheet. Supply compressed air pressure only after the supply line is properly mounted to the actuator. 3. Connect compressed air supply line according the specification on the product data sheet and; see «Table 4-1». Execution Without solenoid valve 48... -. E24-... Table 4-1 Procedure Connect relevant compressed air line to connection CLOSE. Afterwards, connect relevant compressed air line to connection OPEN. Supply admissible compressed air to connection close first! 14/27 Edition 2016-04-14 809878EA
INSTALLATION 4.4 Electrical connection Electric shock DANGER Parts being under voltage will result in serious injury or death. Do not touch parts being under voltage. Wrong sequence of connections Valve mechanism may get damaged when electrical power is being connected before compressed air is connected. Always connect compressed air before connecting electrical power. Wrong voltage Electrical components may get damaged. Supply electrical components with the correct voltage. 4. Connect position indicator according to product data sheet. 809878EA Edition 2016-04-14 15/27
OPERATION Series 48 5 Operation Unqualified personnel Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. Movable parts Human body parts may get jammed and severely injured. Do not operate before product is installed completely into the vacuum system. 5.1 Normal operation Valve is closed and opened pneumatically. For technical details, see product data sheet. Make sure that compressed air is supplied at the specified pressure; see also chapter «4.3 Compressed air connection». Make sure that the connect voltage is supplied. See also chapter «4.4 Electrical connection». Action Execution Procedure To open the valve Table 5-1 Without solenoid valve 48... -. E24-... Supply compressed air to connection open. Release air through connection closed. 16/27 Edition 2016-04-14 809878EA
OPERATION Action Execution Procedure To close the valve Table 5-2 Without solenoid valve 48... -. E24-... Supply compressed air to connection close. Release air through connection open. 5.2 Operation under increased temperature Maximum allowed temperature, see product data sheet. Inconstant temperatures Performance of the valve may deteriorate. Actuate valve only after the bake-out temperature has been stable for two hours. If valve must be actuated during bake-out, make sure that the heating or cooling rate does not exceed 10 C per hour in the temperature range Make sure that the temperature differences over the whole body do not exceed 30 C. 809878EA Edition 2016-04-14 17/27
OPERATION Series 48 5.3 Bake-out Valve inside under vacuum pressure 10-5 mbar to prevent oxidation. Bellows interspace either under vacuum pressure 10-5 mbar or filled with an inert gas to prevent oxidation. Maximum temperature difference among all baked valve components shall not exceed 30 C. Specification Valve body: 240 C in open and closed position Actuator: 140 C for max.100 h * Position indicator: 200 C Heating and cooling rate: Table 5-3 10 C / h * Applied high temperatures and radiation exposure are weakening the sealing materials of the actuator. A combination of both will shorten the lifetime. 5.4 Behavior in case of air pressure drop Valve closed: Valve open: Valve remains closed and leak tight. Valve position is undefined. 5.5 Behavior in case of power failure Valve closed or open: Depending on customer control. 18/27 Edition 2016-04-14 809878EA
OPERATION 5.6 Trouble shooting Failure Check Action See Valve mechanism does not move Air pressure Operating pressure Connect compressed air Adjust operating pressure «4.3 Compressed air connection» «4.3 Compressed air connection» Leak at gate Condition of gate seal Please contact VAT www.vatvalve.com Condition of valve gate Please contact VAT www.vatvalve.com Operating pressure Adjust operating pressure «4.3 Compressed air connection» Leak at body Whistling sound during opening or closing Condition of bonnet seal and sealing surface Condition of bellows Please contact VAT Please contact VAT No action required when valve is actuated at atmosphere No action required when valve is actuated in vacuum as long as the sound is not excessive www.vatvalve.com www.vatvalve.com Table 5-4 If you need any further information, please contact one of our service centers. You will find the addresses on our website www.vatvalve.com. 809878EA Edition 2016-04-14 19/27
MAINTENANCE Series 48 6 Maintenance Unqualified personnel 6.1 Maintenance intervals Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. Under clean operating conditions the valve does not require any maintenance during the specified life cycle. Impacts from the process may require more frequent maintenance. When the valve has reached the specified life cycle; see product data sheet, we recommend to have it serviced by VAT or specially trained service staff of the customer. Please contact your nearest VAT service center to get recommendations and an offer. You will find the addresses on our website www.vatvalve.com. 20/27 Edition 2016-04-14 809878EA
REPAIRS 7 Repairs Repairs may only be carried out by the VAT service staff or specially trained service staff of the customer. Please contact one of our service centers. You will find the addresses on our website www.vatvalve.com. 809878EA Edition 2016-04-14 21/27
DISMOUNTING AND STORAGE Series 48 8 Dismounting and Storage Unqualified personnel Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. Heavy weight Physical overstraining. Use a crane to lift the product. Hazardous components Human body parts may get jammed and severely injured. Before dismounting the product: disconnect compressed air supply disconnect electrical power supply Movable parts Human body parts may get jammed and severely injured. Keep human body parts away from movable parts. Contamination Product may get contaminated. Always wear cleanroom gloves when handling the product. 22/27 Edition 2016-04-14 809878EA
DISMOUNTING AND STORAGE 8.1 Dismounting 1. Close valve. Valve in open position Valve mechanism may get damaged if valve is in open position. Close valve before dismounting the valve from the system. 2. Disconnect compressed air supply. After disconnecting the compressed air, make sure that the actuator is depressurized! 3. Disconnect electrical power supply. 4. Dismount valve according chapter «4 Installation», however in reverse order. Observe safety instruction of chapter «4 Installation». 8.2 Storage Wrong storage Inappropriate temperatures and humidity may cause damage to the product. Valve must be stored at: relative humidity between 10% and 70% temperature between +10 C and +50 C non-condensing environment Inappropriate packaging Product may get damaged if inappropriate packaging material is used. Always use the original packaging material and handle product with care. 1. Clean / decontaminate valve. 2. Mount protective covers on flanges; see chapter «4.2.1 Preparation for installation». 3. Pack valve appropriately, by using the original packaging material. 809878EA Edition 2016-04-14 23/27
PACKAGING AND TRANSPORT Series 48 9 Packaging and Transport Unqualified personnel Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. Harmful substances Risk of injury in case of contact with harmful substances. Remove harmful substances (e. g. toxic, caustic or microbiological ones) from valve before you return the valve to VAT. Heavy weight Physical overstraining. Use a crane to lift the product. Inappropriate packaging Product may get damaged if inappropriate packaging material is used. Always use the original packaging material and handle product with care. When returning products to VAT, please fill out the VAT form «Declaration of Chemical Contamination» and send it to VAT in advance. The form can be downloaded from our website www.vatvalve.com. If products are radioactively contaminated, the VAT form «Contamination and Radiation Report» must be filled out. Please contact VAT in advance. If products are sent to VAT in contaminated condition, VAT will carry out the decontamination procedure at the customer's expense. 24/27 Edition 2016-04-14 809878EA
PACKAGING AND TRANSPORT 9.1 Packaging Valve in open position Valve mechanism may get damaged if valve is in open position. Make sure that the valve is closed. 1. Mount protective covers on flanges; see chapter «4.2.1 Preparation for installation». 2. Pack valve appropriately, by using the original packaging material. VAT disclaims any liability for damages resulting from inappropriate packaging. 9.2 Transport Inappropriate packaging Product may get damaged if inappropriate packaging material is used. Always use the original packaging material and handle product with care. VAT disclaims any liability for damages resulting from inappropriate packaging. 809878EA Edition 2016-04-14 25/27
DISPOSAL Series 48 10 Disposal Harmful substances Environmental pollution. Discard products and parts according to the local regulations. 26/27 Edition 2016-04-14 809878EA
SPARE PARTS 11 Spare parts Non-original spare parts Non-original spare parts may cause damage to the product. Use original spare parts from VAT only. Parts may only be replaced by the VAT service staff or specially trained service staff of the customer. Please contact one of our service centers and specify the fabrication number of the product; see chapter «1.1 Identification of product». You will find the addresses on our website www.vatvalve.com. 809878EA Edition 2016-04-14 27/27